CN102017171A - Substrates for photovoltaics - Google Patents
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Abstract
Description
本申请要求2008年3月25日提交的美国专利临时申请第61/039,398号的优先权。This application claims priority to US Patent Provisional Application No. 61/039,398, filed March 25, 2008.
背景技术Background technique
发明领域field of invention
实施方式一般涉及光生伏打电池,更具体涉及用于光生伏打电池的光散射基材和覆材(superstrate)。Embodiments relate generally to photovoltaic cells, and more particularly to light scattering substrates and superstrates for photovoltaic cells.
背景技术Background technique
对于薄膜硅光生伏打太阳能电池,光优选有效地结合入硅层,然后被俘获在该层中,提供足够进行光吸收的路径长度。特别优选大于硅厚度的光路长度。For thin film silicon photovoltaic solar cells, light is preferably efficiently incorporated into the silicon layer, where it is then trapped, providing sufficient path length for light absorption. Particular preference is given to optical path lengths which are greater than the thickness of the silicon.
结合了无定形硅和微晶硅的常规串联电池通常包括:在其上设置有透明电极的基材,无定形硅的顶部电池,微晶硅的底部电池,以及背面接触或对电极。光通常从沉积基材一侧入射,使得基材在此电池结构中作为覆材。Conventional tandem cells combining amorphous silicon and microcrystalline silicon typically include: a substrate on which a transparent electrode is disposed, a top cell of amorphous silicon, a bottom cell of microcrystalline silicon, and a back contact or counter electrode. Light is typically incident from the side of the deposition substrate such that the substrate acts as a superstrate in this cell structure.
无定形硅主要在低于700纳米(nm)的光谱可见光部分吸收,而微晶硅的吸收与大块晶体硅类似,随着向延伸至大约1200纳米的过程,吸光率逐渐降低。这两种材料都能够由具有提高的散射和/或改进的透射的表面获益。Amorphous silicon absorbs mainly in the visible part of the spectrum below 700 nanometers (nm), while microcrystalline silicon absorbs similarly to bulk crystalline silicon, with a gradual decrease in absorbance as it extends to about 1200 nm. Both materials can benefit from surfaces with increased scattering and/or improved transmission.
透明电极(也称为透明导电氧化物,TCO)通常是氟掺杂的SnO2膜(FTO)或者铝掺杂的或硼掺杂的ZnO(分别为AZO或BZO)膜,厚度约为1微米,对其进行织构化,用来将光散射入无定形Si和微晶Si。散射的主要测量方式称为“雾度”,定义为散射到进入电池的光束2.5度以外的光与向前透射过电池的全部的光之比。由于散射表面对波长的依赖性,在300-1200纳米的很宽的太阳光谱范围内,雾度通常不是恒定的值。另外,如上文所述,对单次通过硅的均匀薄层而吸收的光,对长波长光的俘获要比对短波长光的俘获更重要。The transparent electrode (also known as transparent conducting oxide, TCO) is usually a fluorine-doped SnO2 film (FTO) or an aluminum-doped or boron-doped ZnO (AZO or BZO, respectively) film with a thickness of about 1 μm , which are textured to scatter light into amorphous Si and microcrystalline Si. The primary measure of scattering is called "haze" and is defined as the ratio of the light scattered beyond 2.5 degrees of the beam entering the cell to the total light transmitted forward through the cell. Due to the wavelength dependence of the scattering surface, the haze is generally not a constant value over the broad solar spectrum from 300-1200 nm. In addition, as noted above, for light absorbed by a single pass through a uniform thin layer of silicon, the trapping of long wavelength light is more important than the trapping of short wavelength light.
在一些常规的光生伏打应用中,在550纳米波长处测得,雾度约为10-15%。但是,所述散射分布函数(distribution function)并不是仅由这一个参数支配的,相对于窄角散射,大角散射能够更有效地提高在硅内的路径长度。对于不同种类的分布函数的文献表明,改进的大角散射对电池的性能具有显著的影响。In some conventional photovoltaic applications, the haze is about 10-15%, measured at a wavelength of 550 nm. However, the distribution function is not governed by this one parameter alone, large angle scattering is more effective at increasing path lengths in silicon than narrow angle scattering. The literature for different kinds of distribution functions shows that improved large-angle scattering has a significant impact on the performance of the cell.
可以通过各种技术对TCO表面进行织构化。例如,对于FTO,可以通过用来沉积膜的化学气相沉积法(CVD)的参数来控制织构。对于AZO或BZO,通常在沉积之后采用等离子体处理或者湿法蚀刻形成所需的形貌。TCO surfaces can be textured by various techniques. For example, for FTO, the texture can be controlled by the parameters of the chemical vapor deposition (CVD) method used to deposit the film. For AZO or BZO, plasma treatment or wet etching is usually used after deposition to form the desired morphology.
在过去,雾度通常写作单个数字的形式。长波长响应对微晶硅是特别重要的。更近些时候,报道了随波长变化的雾度值。因为散射与波长和散射体的尺寸直接相关,所以可以通过改变织构化的表面上的特征的尺寸来改良波长响应。可以在单个织构中将大的特征尺寸和小的特征尺寸结合起来,同时在长波长和短波长提供散射。这样的结构还将光俘获的功能性与改进的透光性相结合。另一方面,对于无定形Si,较短的波长是有益的。In the past, haze was usually written as a single number. The long wavelength response is particularly important for microcrystalline silicon. More recently, haze values as a function of wavelength have been reported. Because scattering is directly related to wavelength and the size of the scatterers, the wavelength response can be improved by changing the size of the features on the textured surface. Large and small feature sizes can be combined in a single texture while providing scattering at long and short wavelengths. Such structures also combine light-trapping functionality with improved light transmission. On the other hand, for amorphous Si, shorter wavelengths are beneficial.
织构化的TCO技术可能包括以下的一种或多种缺点:1)织构的粗糙结构会降低沉积的硅的质量,造成电短路,从而降低太阳能电池的总体性能;2)织构的最优化同时受到沉积或蚀刻工艺可以形成的织构以及与较厚的TCO层相关的透光性降低的限制;以及3)对于ZnO的情况,为了制造织构而采用等离子体处理或湿法蚀刻会增加成本。Textured TCO technology may include one or more of the following disadvantages: 1) the rough structure of the texture can degrade the quality of the deposited silicon, causing electrical shorts, thereby reducing the overall performance of the solar cell; Optimization is limited by both the texture that can be formed by the deposition or etching process and the reduction in light transmission associated with thicker TCO layers; and 3) in the case of ZnO, the use of plasma treatment or wet etching to create the texture would increase cost.
另一种满足薄膜硅太阳能电池的光俘获需求的方法是在沉积氮化硅之前,对硅下方的基材进行织构化,而不是对沉积的膜进行织构化。在一些常规的薄膜硅太阳能电池中,采用通孔代替TCO,用以与接触基材的Si的底部形成接触。一些常规的薄膜硅太阳能电池中的织构化由沉积在平面玻璃基材上的粘结剂基质中的SiO2颗粒组成。此类织构化通常使用溶胶-凝胶法完成,其中颗粒悬浮在液体中,牵拉基材通过液体,然后进行烧结。珠粒保持球形,通过烧结的凝胶保持在原位。Another approach to meeting the light-trapping needs of thin-film silicon solar cells is to texture the substrate beneath the silicon prior to deposition of silicon nitride, rather than texturing the deposited film. In some conventional thin film silicon solar cells, vias are used instead of TCOs to make contact with the bottom of the Si that contacts the substrate. The texturing in some conventional thin-film silicon solar cells consists of SiO2 particles deposited in a binder matrix on a planar glass substrate. Such texturing is typically accomplished using a sol-gel process, in which particles are suspended in a liquid, the substrate is pulled through the liquid, and then sintered. The beads remain spherical, held in place by the sintered gel.
织构化的玻璃基材法可能包括以下的一种或多种缺点:1)需要溶胶-凝胶化学方法和相关的工艺以提供玻璃微球体与基材的结合;2)所述工艺在玻璃基材的两个侧面上形成织构化的表面;3)与氧化硅微球体和溶胶-凝胶材料相关的额外成本;以及4)硅膜中膜粘着性和/或形成裂纹的问题。Textured glass substrate methods may include one or more of the following disadvantages: 1) sol-gel chemistry and related processes are required to provide bonding of the glass microspheres to the substrate; 3) additional costs associated with silica microspheres and sol-gel materials; and 4) problems with film adhesion and/or crack formation in silicon films.
人们已经开发了许多另外的方法,在TCO沉积之前制造织构化的表面。这些方法包括喷砂,聚苯乙烯微球体沉积和蚀刻,以及化学蚀刻。这些涉及织构化的表面的方法可能在可以形成的表面织构种类方面受到限制。Many additional methods have been developed to produce textured surfaces prior to TCO deposition. These methods include sandblasting, polystyrene microsphere deposition and etching, and chemical etching. These methods involving textured surfaces may be limited in the kinds of surface textures that can be formed.
对于Si厚度约小于100微米的大块晶体Si太阳能电池,光俘获也是有利的。在此厚度之下,厚度不足,无法在单次通过或两次通过(具有反射性背面接触件)的情况下有效地吸收所有的太阳辐射。因此,已经开发出了具有大规模几何结构的覆盖玻璃,用来提高光俘获。例如,在覆盖玻璃和硅之间设置EVA(乙基-乙酸乙烯酯)包封材料。这些覆盖玻璃的一个例子是购自圣戈本玻璃公司(Saint-Gobain Glass)的类产品。通常采用辊压法形成该大规模结构。Light trapping is also advantageous for bulk crystalline Si solar cells where the Si thickness is less than about 100 microns. Below this thickness, there is not enough thickness to efficiently absorb all of the solar radiation in a single pass or in two passes (with reflective back contacts). Therefore, cover glasses with large-scale geometries have been developed to enhance light trapping. For example, an EVA (ethyl-vinyl acetate) encapsulant is provided between the cover glass and the silicon. An example of these cover glasses is available from Saint-Gobain Glass (Saint-Gobain Glass) class products. The large-scale structure is usually formed using a rolling method.
优选使用具有光散射性质的基材,所述光散射性质要足以提供光俘获,特别是较长波长的光俘获。另外,优选基材是平面型的,例如可以在不导致有害的电子效应的前提下随后进行膜沉积。It is preferred to use a substrate having light scattering properties sufficient to provide light trapping, especially longer wavelength light trapping. In addition, it is preferred that the substrate is planar, for example to allow subsequent film deposition without causing deleterious electronic effects.
发明内容Contents of the invention
如本文所述的基材解决了上述用于光生伏打应用的常规基材的一个或多个缺点。The substrates as described herein address one or more of the disadvantages of conventional substrates for photovoltaic applications described above.
一个实施方式是一种光生伏打装置,该装置包括基材,与基材相邻的导电材料,以及与所述导电材料相邻的活性光生伏打介质,所述基材包含无机基质,以及设置在所述无机基质中的具有光散射性质的区域。One embodiment is a photovoltaic device comprising a substrate, a conductive material adjacent to the substrate, and an active photovoltaic medium adjacent to the conductive material, the substrate comprising an inorganic matrix, and A region having light-scattering properties disposed in the inorganic matrix.
另一个实施方式是一种光生伏打装置,该装置包括基材,一个层,导电材料,以及与所述导电材料相邻的活性光生伏打介质,所述层包含无机基质以及设置在所述无机基质中的具有光散射性质的区域,在所述导电材料中,所述层与所述基材物理接触,所述层设置在所述基材和所述导电材料之间。Another embodiment is a photovoltaic device comprising a substrate, a layer, a conductive material, and an active photovoltaic medium adjacent to the conductive material, the layer comprising an inorganic matrix and disposed on the A region in an inorganic matrix having light-scattering properties in which the layer is in physical contact with the substrate and in which the layer is disposed between the substrate and the conductive material.
在以下的详细描述中提出了本发明的附加特征和优点,其中的部分特征和优点对本领域的技术人员而言由所述内容而容易理解,或通过示出的描述和其权利要求书以及附图中所述实施本发明而被认可。Additional features and advantages of the present invention are set forth in the following detailed description, some of which are readily understood by those skilled in the art from the stated content, or through the illustrated description and its claims and appended It is recognized that the invention is practiced as described in the figures.
应理解前面的一般性描述和以下的详细描述都只是对本发明的示例,用来提供理解本发明的性质和特性的总体评述或框架。It is to be understood that both the foregoing general description and the following detailed description are examples of the invention, and are provided to provide a general overview or framework for understanding the nature and character of the invention.
包括的附图提供了对本发明的进一步的理解,附图被结合在本说明书中并构成说明书的一部分。附图图示说明了本发明的一个或多个实施方式,并与说明书一起用来说明本发明的原理和操作。The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments of the invention, and together with the description serve to explain the principles and operations of the invention.
附图说明Description of drawings
结合附图,通过以下详述更好地理解本发明。The present invention can be better understood from the following detailed description when read in conjunction with the accompanying drawings.
图1是根据一个实施方式的光生伏打装置的特征的示意图。FIG. 1 is a schematic diagram of features of a photovoltaic device according to one embodiment.
图2是根据一个实施方式的光生伏打装置的特征的示意图。Figure 2 is a schematic diagram of features of a photovoltaic device according to one embodiment.
图3是根据一个实施方式的光生伏打装置的特征的示意图。3 is a schematic diagram of features of a photovoltaic device according to one embodiment.
图4a,图4b,图4c和图4d显示了根据一些实施方式的散射基材。Figures 4a, 4b, 4c and 4d show scattering substrates according to some embodiments.
图5是根据一些实施方式示例性的颗粒形状、分布和尺寸的扫描电子显微照片(SEM)。Figure 5 is a scanning electron micrograph (SEM) of exemplary particle shapes, distributions and sizes, according to some embodiments.
图6是根据一些实施方式示例性的颗粒形状、分布和尺寸的扫描电子显微照片(SEM)。Figure 6 is a scanning electron micrograph (SEM) of exemplary particle shapes, distributions and sizes, according to some embodiments.
图7是根据一些实施方式示例性的颗粒形状、分布和尺寸的扫描电子显微照片(SEM)。Figure 7 is a scanning electron micrograph (SEM) of exemplary particle shapes, distributions and sizes, according to some embodiments.
图8是直径为500纳米的颗粒的空气透射率随颗粒密度的变化关系图。Figure 8 is a graph showing the air transmittance as a function of particle density for particles with a diameter of 500 nanometers.
图9是对于直径500纳米的颗粒,被积函数(Si吸光率,太阳光谱和波长的乘积)-波长的关系图。Figure 9 is a plot of the integrand (Si absorbance, product of solar spectrum and wavelength) versus wavelength for particles with a diameter of 500 nm.
图10是对于5e6的最优化的颗粒密度,透射率-反射率图。Figure 10 is a graph of the optimized particle density, transmittance-reflectance for 5e6.
图11是对于5e6的最优化的颗粒密度,相应的角强度图。Figure 11 is a plot of the corresponding angular intensity for an optimized particle density of 5e6.
图12是根据一个实施方式,使用光敏性玻璃得到的基材的透射率-波长图。Figure 12 is a graph of transmittance versus wavelength for a substrate obtained using photosensitive glass, according to one embodiment.
图13是根据一个实施方式的Fota-LiteTM基材的角强度图。Figure 13 is a graph of the angular strength of a Fota-Lite ™ substrate according to one embodiment.
图14是根据一个实施方式,总透射率-波长图。Figure 14 is a graph of total transmittance versus wavelength, according to one embodiment.
图15是根据一个实施方式,漫透射率-波长图。Figure 15 is a graph of diffuse transmittance versus wavelength, according to one embodiment.
图16是根据一个实施方式的层的角强度图。Figure 16 is a graph of the angular intensity of a layer according to one embodiment.
发明详述Detailed description of the invention
下面详细参考本发明的各种实施方式,这些实施方式的例子在附图中示出。只要可能,在所有附图中使用相同的附图标记来表示相同或类似的部分。Reference will now be made in detail to various embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
在本文中,术语“体积散射”可以定义为光通过的材料的折射率的非均一性造成的对光路的影响。In this context, the term "volume scattering" can be defined as the effect on the optical path caused by the non-uniformity of the refractive index of the material through which light passes.
在本文中,术语“表面散射”可以定义为光生伏打电池中层间的界面粗糙度对光路造成的影响。In this paper, the term "surface scattering" can be defined as the effect of the roughness of the interface between layers in a photovoltaic cell on the light path.
在本文中,根据光生伏打电池的结构,术语“基材”可以用来描述基材或者覆材(superstrate)。例如,如果当所述基材在组装入光生伏打电池的时候,位于光生伏打电池的光入射侧,则所述基材是覆材。所述覆材可以为光生伏打材料提供保护,使其免受冲击和环境降解,同时允许太阳光谱中合适的波长透过。另外,可以将多个光生伏打电池排列成光生伏打模块。Herein, the term "substrate" may be used to describe either the substrate or the superstrate, depending on the structure of the photovoltaic cell. For example, the substrate is a superstrate if the substrate is located on the light incident side of the photovoltaic cell when assembled into the photovoltaic cell. The covering can provide protection for the photovoltaic material from impact and environmental degradation while allowing transmission of suitable wavelengths in the solar spectrum. In addition, a plurality of photovoltaic cells can be arranged into a photovoltaic module.
在本文中,术语“相邻的”可以定义为紧邻。相邻的结构可以互相物理接触,也可以不发生物理接触。相邻的结构可以包括设置在它们之间的其它的层以及/或者结构。As used herein, the term "adjacent" may be defined as immediately adjacent. Adjacent structures may or may not be in physical contact with each other. Adjacent structures may include other layers and/or structures disposed therebetween.
在本文中,术语“平面的”可以定义为具有基本上形态平坦的表面。As used herein, the term "planar" may be defined as having a surface that is substantially flat in shape.
如图1所示,一个实施方式是一种光生伏打装置100,该装置包括基材10,与基材相邻的导电材料12,以及与所述导电材料相邻的活性光生伏打介质14,所述基材包含无机基质18,以及设置在所述无机基质中的具有光散射性质的区域20。As shown in FIG. 1, one embodiment is a
在一个实施方式中,同样如图1所示,所述光生伏打装置100还包括对电极16,所述对电极与所述活性光生伏打介质14物理接触,所述对电极设置在所述活性光生伏打介质14的相反表面22上,作为导电材料12。In one embodiment, as also shown in FIG. 1 , the
根据一个实施方式,所述活性光生伏打介质与导电材料物理接触。根据一个实施方式,所述导电材料是透明导电膜,例如透明导电氧化物。所述透明导电膜可以包括织构化的表面。According to one embodiment, the active photovoltaic medium is in physical contact with the electrically conductive material. According to one embodiment, the conductive material is a transparent conductive film, such as a transparent conductive oxide. The transparent conductive film may include a textured surface.
根据一个实施方式,所述区域包含以下的一种或多种:颗粒、团体、球体、沉淀物、晶体、枝状晶体、相分离元素、相分离化合物、空气泡、空气线条、空穴或它们的组合。或者例如所述区域可以包含多种颗粒、多种团体、多种球体、多种沉淀物、多种晶体、多种枝状晶体、多种相分离元素、多种相分离化合物、多种空气泡、多种空气线条、多种空穴或它们的组合。According to one embodiment, said regions comprise one or more of the following: particles, bodies, spheres, precipitates, crystals, dendrites, phase-separated elements, phase-separated compounds, air bubbles, air lines, cavities or their The combination. Or for example the region may comprise particles, groups, spheres, precipitates, crystals, dendrites, phase-separated elements, phase-separated compounds, air bubbles , a variety of air lines, a variety of cavities, or a combination thereof.
在一个实施方式中,所述基质包含选自以下的材料:玻璃、玻璃陶瓷以及它们的组合。在一个实施方式中,所述区域包含选自以下的材料:玻璃、玻璃陶瓷、陶瓷、金属氧化物、混合金属氧化物(metals oxide)、以及它们的组合。In one embodiment, the matrix comprises a material selected from the group consisting of glass, glass-ceramic, and combinations thereof. In one embodiment, the region comprises a material selected from the group consisting of glass, glass ceramics, ceramics, metal oxides, metals oxides, and combinations thereof.
如图2的一个实施方式所示,所述光生伏打装置200还包括一个层24,所述层24包含无机基质28以及设置在所述无机基质中的具有光散射性质的区域26,所述层与基材10物理接触,设置在所述基材10和导电材料12之间。As shown in one embodiment of FIG. 2 , the
根据一些实施方式,所述层的厚度等于或小于1毫米,例如等于或小于800微米,例如等于或小于500微米,例如等于或小于250微米,例如等于或小于100微米,例如等于或小于50微米,例如等于或小于25微米,例如等于或小于15微米,例如等于或小于10微米。根据另一个实施方式,所述层的厚度等于或大于1微米,例如为1-10微米。According to some embodiments, the layer has a thickness equal to or less than 1 mm, such as equal to or less than 800 microns, such as equal to or less than 500 microns, such as equal to or less than 250 microns, such as equal to or less than 100 microns, such as equal to or less than 50 microns , such as equal to or less than 25 microns, such as equal to or less than 15 microns, such as equal to or less than 10 microns. According to another embodiment, said layer has a thickness equal to or greater than 1 micrometer, for example 1-10 micrometers.
在一些实施方式中,所述活性光生伏打介质包括多个层。例如,所述多个层可以包含一个或多个p-n结,例如在Si电池内。在一个实施方式中,所述活性光生伏打介质包含串联结,CdTe,或(二)硒化铜铟镓(CIGS)。In some embodiments, the active photovoltaic medium includes multiple layers. For example, the plurality of layers may comprise one or more p-n junctions, such as in a Si cell. In one embodiment, the active photovoltaic medium comprises a tandem junction, CdTe, or (di)copper indium gallium selenide (CIGS).
图3所示的另一个实施方式是一种光生伏打装置300,所述装置包括基材30,一个层32,导电材料12,以及与所述导电材料相邻的活性光生伏打介质14,所述层32包含无机基质28以及设置在所述无机基质中的具有光散射性质的区域26,在所述导电材料12中,所述层与所述基材30物理接触,所述层设置在所述基材和所述导电材料之间。Another embodiment shown in FIG. 3 is a
根据一些实施方式,所述层的厚度等于或小于1毫米,例如等于或小于800微米,例如等于或小于500微米,例如等于或小于250微米,例如等于或小于100微米,例如等于或小于50微米,例如等于或小于25微米,例如等于或小于15微米,例如等于或小于10微米。根据另一个实施方式,所述层的厚度等于或大于1微米,例如为1-10微米。According to some embodiments, the layer has a thickness equal to or less than 1 mm, such as equal to or less than 800 microns, such as equal to or less than 500 microns, such as equal to or less than 250 microns, such as equal to or less than 100 microns, such as equal to or less than 50 microns , such as equal to or less than 25 microns, such as equal to or less than 15 microns, such as equal to or less than 10 microns. According to another embodiment, said layer has a thickness equal to or greater than 1 micrometer, for example 1-10 micrometers.
在一个实施方式中,同样如图3所示,所述光生伏打装置300还包括对电极16,所述对电极与所述活性光生伏打介质14物理接触,位于所述活性光生伏打介质14的相反表面22上,作为导电材料12。In one embodiment, as also shown in FIG. 3 , the
在图3所示的实施方式中,所述基材可以具有体积散射性质,也可没有体积散射性质。根据一个实施方式,所述基材是透明的。根据一个实施方式,所述基材包含选自以下的材料:玻璃、玻璃陶瓷以及它们的组合。In the embodiment shown in FIG. 3, the substrate may or may not have volume scattering properties. According to one embodiment, the substrate is transparent. According to one embodiment, the substrate comprises a material selected from the group consisting of glass, glass ceramics and combinations thereof.
如上所述,常规的硅光生伏打电池使用结构化的表面作为在硅层内使得光重新取向以及提高光路长度的手段。一种替代的方法是在平面基材内使用体积散射。这些材料已经被用于光散射应用。常规的例子包括乳色玻璃和玻璃陶瓷。As noted above, conventional silicon photovoltaic cells use a structured surface as a means of reorienting light within the silicon layer and increasing the optical path length. An alternative approach is to use volumetric scattering within a planar substrate. These materials have been used in light scattering applications. Common examples include opal glasses and glass ceramics.
在一个实施方式中,所述基材包括分散在无机基质整个体积内的大量区域。在另一个实施方式中,所述基材包括分散在无机基质一部分体积内的大量区域。此处可以进一步获得以下优点:在保持平面的表面用于随后的沉积(例如沉积TCO)的同时,对基材内的散射区域进行图案化。In one embodiment, the substrate comprises a plurality of domains dispersed throughout the volume of the inorganic matrix. In another embodiment, the substrate comprises a plurality of domains dispersed within a portion of the volume of the inorganic matrix. A further advantage can be obtained here of patterning the scattering regions within the substrate while maintaining a planar surface for subsequent deposition, eg deposition of TCO.
在一些实施方式中,所述基材包括一些按照以下方式、以一定的梯度设置的区域:在厚度上从顶到底,在厚度上从左到右,在厚度的一部分上从顶到底,在厚度的一部分上从左到右,或者这些情况的组合。以一种或多种图案设置的区域还可以在所述一种或多种图案内包括上文所述的梯度。图4a,图4b,图4c和图4d中显示了包括区域的基材10的示例性实施方式。根据一些实施方式,基质材料、区域结构、区域材料和区域的设置可以与前文所述相同。In some embodiments, the substrate includes regions arranged in a gradient in the following manner: from top to bottom in thickness, from left to right in thickness, from top to bottom over a portion of thickness, in thickness Part of the left to right, or a combination of these cases. Regions arranged in one or more patterns may also include the gradients described above within the one or more patterns. Exemplary embodiments of
具有图案化的区域的基材或层可以在基材的非散射部分内提供光俘获,同时在Si内提供光俘获。在各种实施方式中,所述散射层可以通过以下方法形成:层叠,层叠熔合,薄膜沉积,或者光引发的结晶(例如Fota-LiteTM)。在一个实施方式中,可以通过将高(或低)折射率的微型颗粒或微球体嵌入平面化的薄层中,从而形成散射层或膜。在一个实施方式中,所述整体或薄层体积散射材料是相分离的玻璃或玻璃陶瓷。A substrate or layer with patterned regions can provide light trapping in the non-scattering portion of the substrate while providing light trapping in the Si. In various embodiments, the scattering layer can be formed by lamination, lamination fusion, thin film deposition, or photo-induced crystallization (eg, Fota-Lite ™ ). In one embodiment, the scattering layer or film can be formed by embedding high (or low) refractive index microparticles or microspheres in a thin planarized layer. In one embodiment, the bulk or thin layer volume scattering material is a phase separated glass or glass ceramic.
有很多种材料适合用作体积散射基材和/或层。合适的材料包括玻璃陶瓷,其包括但不限于例如富铝红柱石,β-石英,硅锌矿,硅碱钙石和DicorTM;相分离的玻璃(例如蛋白石)包括但不限于例如钡蛋白石,硅酸钡蛋白石,氟化物蛋白石和硅酸铅蛋白石;光敏性玻璃,包括但不限于例如FotaliteTM和FotaFormTM(购自康宁有限公司(Corning Incorporated));以及光折射材料(包括玻璃、玻璃陶瓷和晶体)。There are a wide variety of materials suitable for use as volume scattering substrates and/or layers. Suitable materials include glass ceramics including, but not limited to, e.g., mullite, beta-quartz, willemite, wollastonite, and Dicor ™ ; phase-separated glasses (e.g., opal) including, but not limited to, e.g., barium opal, silica barium acid opal, fluoride opal, and lead silicate opal; photosensitive glasses, including but not limited to, for example, Fotalite ™ and FotaForm ™ (available from Corning Incorporated); and photorefractive materials (including glass, glass-ceramic, and crystal).
在所述各种材料中,散射颗粒可以由均一的材料原位形成,或者加入,以制备复合混合物。所述材料可以使用合适的加工技术熔融,包括热加工技术(例如加热),化学加工技术(例如离子交换)以及/或者光敏技术(例如UV,紫外,和/或激光照射)。在一些实施方式中,通过以下技术形成体积散射结构:例如光刻技术,使得材料物理取向(例如通过拉伸之类的机械方式,或者通过在基材上施加热梯度的热学方式),或者通过对表面层进行离子交换。在一个实施方式中,加工技术使得基材材料发生相分离。在一个实施方式中,加工技术使得基材中产生沉淀。在一个实施方式中,加工技术导致形成两相介质。Among the various materials, the scattering particles can be formed in situ from a homogeneous material, or added to make a composite mixture. The material can be melted using suitable processing techniques, including thermal processing techniques (eg, heating), chemical processing techniques (eg, ion exchange), and/or photosensitive techniques (eg, UV, ultraviolet, and/or laser irradiation). In some embodiments, volume scattering structures are formed by techniques such as photolithography, which allow the material to be physically oriented (e.g., mechanically, such as by stretching, or thermally, by applying a thermal gradient across the substrate), or by Ion exchange is performed on the surface layer. In one embodiment, the processing technique is such that the substrate material phase separates. In one embodiment, the processing technique results in precipitation in the substrate. In one embodiment, the processing technique results in the formation of a two-phase media.
在光敏性玻璃中,例如FotaLiteTM中,可以通过控制曝光的时间、区域和强度来控制一个或多个体积散射区域的深度和图案。In photosensitive glasses, such as FotaLite (TM) , the depth and pattern of one or more volumetric scattering regions can be controlled by controlling the time, area and intensity of exposure.
根据基材所需的性质(例如散射角,透射率和波长依赖性),可以使用很多种材料。在PV应用中,所需的性质通常包括广角散射,高透射率,以及不依赖于波长的性质。所述各种性质会受到散射颗粒尺寸、形状和分布影响。图5、图6和图7中显示了示例性的颗粒形状和尺寸,图中分别显示了玻璃陶瓷,富铝红柱石和Fota-LiteTM。这些材料可以用作基材,或者可以用作层,或者可以用于基材和层中的一者或两者。A wide variety of materials can be used depending on the desired properties of the substrate such as scattering angle, transmittance and wavelength dependence. In PV applications, desired properties typically include wide-angle scattering, high transmittance, and wavelength-independent properties. The various properties can be affected by the size, shape and distribution of the scattering particles. Exemplary particle shapes and sizes are shown in Figures 5, 6 and 7, showing glass-ceramic, mullite and Fota-Lite ™ , respectively. These materials may be used as a substrate, or may be used as a layer, or may be used for one or both of the substrate and the layer.
在一个实施方式中,基材内的体积散射与粗糙表面(例如对于粗糙化的TCO)的散射相结合,用来获得整体最优化的性能,同时无需使用过于粗糙的表面,以免降低PV电池的性能。在一个实施方式中,提供了粗糙的TCO,以减小预期由于具有不同折射率的平面材料(TCO~2.0,Si~4)造成的菲涅耳反射(Fresnel reflection)。In one embodiment, volumetric scattering within the substrate is combined with scattering from a rough surface (e.g., for a roughened TCO) to achieve overall optimized performance without using an overly rough surface that degrades the PV cell. performance. In one embodiment, a rough TCO is provided to reduce Fresnel reflections expected from planar materials with different refractive indices (TCO~2.0, Si~4).
对于薄的(<~100微米),大块Si的情况,用EVA代替TCO,而Si要厚得多。与薄膜Si的情况相同,在透射性和光俘获所需的散射性之间进行权衡。在此情况下,在可见光波长范围内具有高透射性似乎是更关键的,因为在这些厚度之下,仅需要在Si所吸收的最长波长处进行光俘获。In the case of thin (<~100 microns), bulk Si, EVA is used instead of TCO, while Si is much thicker. As in the case of thin-film Si, there is a trade-off between transmittance and scattering required for light trapping. In this case, high transmission in the visible wavelength range appears to be more critical, since below these thicknesses light trapping is only required at the longest wavelengths absorbed by Si.
根据一个实施方式,所述基材是平坦的。在一个实施方式中,所述层是平坦的。根据另一个实施方式,所述基材和层的组合是平坦的。使用体积散射平坦基材进行光散射的一个优点在于,能够克服结构化的基材的电学和晶体生长缺陷。通过改进硅的质量,可以直接导致太阳能电池的性能获得提高。对于需要透明导电性电极的薄膜技术,TCO不需要具有双模织构,因此可以是使用在线和连续CVD系统进行节约成本的沉积的。另外,可以对活性Si薄膜的厚度进行精细调节并减小,以尽可能降低模块沉积成本。According to one embodiment, the substrate is flat. In one embodiment, the layer is flat. According to another embodiment, the substrate and layer combination is planar. One advantage of using volume scattering flat substrates for light scattering is that electrical and crystal growth defects of structured substrates can be overcome. By improving the quality of silicon, it can lead directly to improved performance of solar cells. For thin-film technologies requiring transparent conductive electrodes, TCOs do not need to have a dual-mode texture and thus can be deposited cost-effectively using in-line and continuous CVD systems. Additionally, the thickness of the active Si film can be fine-tuned and reduced to minimize module deposition costs.
对于不需要透明导电电极的薄膜技术,将光约束系统直接整合在玻璃基材内,从而尽可能减少了模块制造步骤的数量,获得了可持久的节约成本的方案。对于薄的整体Si太阳能电池,平面型散射基材提供了以下优点:能够提供光俘获,同时覆材的顶部没有织构,所述织构会暴露于环境,容易积累污垢。根据选择用来制造散射基材的方法,一些实施方式还提供了以下优点:在基材形成之后(例如在一个实施方式中,可熔合成形的蛋白石玻璃基材)无需进行随后的处理步骤。以下所述的制造方法适合用于非常大的可熔合成形的基材,例如康宁有限公司目前生产用于显示器应用的那些。For thin-film technologies that do not require transparent conductive electrodes, the light confinement system is directly integrated within the glass substrate, thereby minimizing the number of module fabrication steps and obtaining a sustainable cost-saving solution. For thin monolithic Si solar cells, planar scattering substrates offer the advantage of being able to provide light trapping without texture on top of the superstrate, which would be exposed to the environment and prone to fouling. Depending on the method chosen to make the scattering substrate, some embodiments also provide the advantage that subsequent processing steps are not required after the substrate is formed (eg, in one embodiment, a fusion-formable opal glass substrate). The fabrication methods described below are suitable for very large fusion formable substrates such as those currently produced by Corning Incorporated for display applications.
体积散射基材能够提供高度分散的光分布。对于薄膜光生伏打(PV)应用,所述体积散射基材的实施方式还可以提供足够的透射性,以吸收入射光。这表明可能有能够与光透射和光俘获竞争的最优的散射量。Volume scattering substrates can provide highly dispersed light distribution. For thin film photovoltaic (PV) applications, embodiments of the volume scattering substrate may also provide sufficient transmission to absorb incident light. This suggests that there may be an optimal amount of scattering that can compete with light transmission and light trapping.
为了对具有分散的体积散射的基材的性能进行评价,构建了简化的电池构造模型,其仅仅由基材以及位于基材之上的1μm的Si构成。另外,Si的背面模拟成在进行背面接触的区域为100%反射性背面。所述玻璃基材的厚度为0.7毫米。该模型忽略了TCO的影响。散射颗粒限定为直径在50-2000纳米,折射率为2.1或1.8,处于折射率为1.51的玻璃内。对于各种粒度,密度发生变化,以尽可能增大最大可以实现的电流密度(MACD)。MACD通过下式I限定:To evaluate the performance of substrates with dispersed volume scattering, a simplified cell configuration model was constructed consisting only of the substrate and 1 μm of Si on top of the substrate. In addition, the backside of the Si is modeled as a 100% reflective backside in the area where the backside contact is made. The thickness of the glass substrate is 0.7 mm. The model ignores the effect of TCO. Scattering particles are defined as having a diameter of 50-2000 nanometers and a refractive index of 2.1 or 1.8 within a glass with a refractive index of 1.51. For various particle sizes, the density was varied to maximize the maximum achievable current density (MACD). MACD is defined by Equation I below:
其中q是元素电荷,h是普朗克常数,c是真空中的光速,A是在Si中的吸光率随波长的变化,IAM1.5G是太阳光谱,λ是波长。从300纳米至1200纳米进行积分。使用MACD,假定Si吸收的每个光子都转化为电子。这很显然是理想情况,忽略了材料和装置的电学性质。但是,其确实表征了装置结构的聚光功效。所述模型使用光学研究学会(Optical Research Associates)的光学工具(LightTools)构建,随后在光学工具外进行Si吸光率和MACD的计算。Where q is the element charge, h is Planck's constant, c is the speed of light in vacuum, A is the absorbance in Si as a function of wavelength, I AM1.5G is the solar spectrum, and λ is the wavelength. Integration was performed from 300 nm to 1200 nm. Using MACD, it is assumed that every photon absorbed by Si is converted into an electron. This is obviously an ideal situation, ignoring the electrical properties of materials and devices. However, it does characterize the light concentrating efficacy of the device structure. The model was built using Optical Research Associates' LightTools, followed by calculations of Si absorbance and MACD outside of LightTools.
对于满足n=2.1的颗粒,其中n是颗粒的折射率,表1显示了最优化的值。粒度是颗粒的直径。For particles satisfying n=2.1, where n is the refractive index of the particle, Table 1 shows the optimized values. Particle size is the diameter of the particle.
表1.Table 1.
对于n=1.8的颗粒,发现获得了类似的改进百分数。For the n=1.8 particles, it was found that a similar percentage improvement was obtained.
200nm,500nm和2000nm的颗粒的MACD的较小的变化可以在模拟误差范围之内。颗粒的折射率不会对结果造成显著影响,但是会改变最优的颗粒密度。表中还显示了相对于不包括散射的基材的改进百分数。这些是初步的结果,说明有可能相对于平坦的无散射的基材获得显著改进。Small variations in the MACD of particles of 200nm, 500nm and 2000nm can be within the error of the simulation. The refractive index of the particles does not significantly affect the results, but does change the optimal particle density. The table also shows the percent improvement over the substrate not including scattering. These are preliminary results, showing that it is possible to obtain significant improvements over flat, non-scattering substrates.
图8提供了一个例子,通过对颗粒密度最优化来获得最佳的PV电池性能(通过MACD决定),该例子使用处于n=1.51的材料中的n=2.1、粒度500纳米的颗粒,其中n是折射率。颗粒密度为1e6至1e7 1/mm3。对于晶体硅的1微米的层,最优化的颗粒密度为5e6 1/mm3。将用来计算MACD的被积函数对三种不同的颗粒密度做图。曲线显示低的值,尤其是对于低颗粒密度,在较长波长下显示低的值;对于最优化颗粒密度的所有波长显示高的值,对于高颗粒密度,在短波长显示低的值,在长波长显示高的值。线条34显示颗粒密度(1/mm3)为1e6的情况下,透射率-波长图。线条36显示颗粒密度(1/mm3)为5e6的情况下,透射率-波长图。线条38显示颗粒密度(1/mm3)为1e7的情况下,透射率-波长图。Figure 8 provides an example of obtaining the best PV cell performance (determined by MACD) by optimizing particle density using particles of 500 nm in size with n=2.1 in a material with n=1.51, where n is the refractive index. The particle density is 1e6 to
结合了这些颗粒密度的玻璃模拟为空气中的厚板,用来评价其透射率、反射率和散射性质。图9显示了总透射率与颗粒密度的变化关系。预期随着颗粒密度增大,通过厚板的总透射率减小。这导致上文所述的被积函数中与波长有关的性质发生移动。在较长波长范围内透射率的减小将从玻璃/Si界面处反射的光重新射向Si,从而提高了较长波长下的Si吸光率。较短波长下透射率的减小抵销了这一益处,因此在这两种效应平衡之处存在吸光率的最优点。线条44显示颗粒密度(1/mm3)为1e6的情况下,被积函数-波长图。线条40显示颗粒密度(1/mm3)为5e6的情况下,被积函数-波长图。线条42显示颗粒密度(1/mm3)为1e7的情况下,被积函数-波长图。The glass incorporating these particle densities was simulated as a slab in air to evaluate its transmittance, reflectivity, and scattering properties. Figure 9 shows the total transmittance as a function of particle density. It is expected that as the particle density increases, the overall transmission through the thick plate decreases. This results in a shift in the wavelength-dependent properties of the integrand described above. The reduction in transmittance in the longer wavelength range redirects light reflected from the glass/Si interface towards Si, thereby increasing the Si absorbance at longer wavelengths. The decrease in transmission at shorter wavelengths offsets this benefit, so there is an optimum in absorbance where the two effects are balanced.
对于最优化的颗粒密度5e6,透射率和反射率示于图10,其中线条46是透射率,线条48是反射率。图11显示了对于最优化的颗粒密度的相应的角度强度曲线,其中显示了强的镜面反射峰,具有宽的角散射底部部分。线条50是透射散射,线条52是反射散射。For an optimized particle density of 5e6, the transmittance and reflectance are shown in Figure 10, where
图12是根据一个实施方式,使用光敏性玻璃得到的基材的透射率-波长图。在此实施例中,光敏性玻璃是Fota-LiteTM,其厚度为2毫米,以10毫焦/脉冲的剂量对248纳米的光曝光。线条54显示曝光10次脉冲的玻璃的总透射率。线条54a显示曝光10次脉冲的玻璃的漫透射率。线条55显示曝光12次脉冲的玻璃的总透射率。线条55a显示曝光12次脉冲的玻璃的漫透射率。线条56显示曝光15次脉冲的玻璃的总透射率。线条56a显示曝光15次脉冲的玻璃的漫透射率。Figure 12 is a graph of transmittance versus wavelength for a substrate obtained using photosensitive glass, according to one embodiment. In this example, the photosensitive glass was Fota-Lite (TM) , 2 mm thick, exposed to 248 nm light at a dose of 10 mJ/pulse. Line 54 shows the total transmission of the glass exposed to 10 pulses. Line 54a shows the diffuse transmission of the glass exposed to 10 pulses. Line 55 shows the total transmission of the glass exposed to 12 pulses. Line 55a shows the diffuse transmission of the glass exposed to 12 pulses. Line 56 shows the total transmission of the glass exposed to 15 pulses. Line 56a shows the diffuse transmission of the glass exposed to 15 pulses.
图13是对400nm,600nm,800nm和1000nm波长的光的12次脉冲曝光的Fota-LiteTM的角度强度余弦校正双向透射函数(ccBTDF)-角度图。图13中显示了很少的镜面反射峰,或着没有镜面反射峰,有很宽的角散射。Figure 13 is a graph of angular intensity cosine corrected bidirectional transmission function (ccBTDF) versus angle for Fota-Lite ™ exposed to 12 pulses of light at wavelengths of 400nm, 600nm, 800nm and 1000nm. Figure 13 shows few or no specular peaks, with wide angle scatter.
图14是根据一个实施方式,一个层的总透射率-波长图,所述层包含复合玻璃基质,所述基质包含TiO2颗粒。制备了样品,其中层包含1%,2.5%,5%和7.5%的TiO2。线条58,线条60,线条62和线条64分别显示包含1%,2.5%,5%和7.5%的TiO2的层的总透射率。14 is a plot of total transmission versus wavelength for a layer comprising a composite glass matrix comprising Ti02 particles, according to one embodiment. Samples were prepared in which the layers contained 1%, 2.5%, 5% and 7.5% TiO2 .
图15是根据一个实施方式,一个层的漫透射率-波长图,所述层包含复合玻璃基质,所述基质包含TiO2颗粒。制备了样品,其中层包含1%,2.5%,5%和7.5%的TiO2。线条66,线条68,线条70和线条72分别显示包含1%,2.5%,5%和7.5%的TiO2的层的漫透射率。15 is a graph of diffuse transmittance versus wavelength for a layer comprising a composite glass matrix comprising Ti02 particles, according to one embodiment. Samples were prepared in which the layers contained 1%, 2.5%, 5% and 7.5% TiO2 .
图16是对450nm,600nm,800nm波长的光的包含1%的TiO2的层的角度强度余弦校正双向透射函数(ccBTDF)-角度图。Figure 16 is a plot of angular intensity cosine corrected bidirectional transmission function (ccBTDF) versus angle for layers containing 1% Ti02 for light at wavelengths of 450nm, 600nm, and 800nm.
可以通过计算漫透射率-总透射率之比来确定雾度。Haze can be determined by calculating the ratio of diffuse transmittance-total transmittance.
对本领域的普通技术人员而言,显而易见的是,可以在不偏离本发明的范围和精神的前提下对本发明进行各种修改和变动。因此,本发明意图覆盖本发明的修改和变动,只要这些修改和变动在所附权利要求及其等同方案的范围之内即可。It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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| CN103137739A (en) * | 2011-11-30 | 2013-06-05 | 杜邦太阳能有限公司 | Solar cell module and BIPV curtain wall with switchable lighting function |
| CN112271227A (en) * | 2020-10-27 | 2021-01-26 | 中国电子科技集团公司第十八研究所 | A glass cover sheet for improving the conversion efficiency of space solar cells |
Also Published As
| Publication number | Publication date |
|---|---|
| EP2257989A2 (en) | 2010-12-08 |
| KR20100125443A (en) | 2010-11-30 |
| EP2259877A2 (en) | 2010-12-15 |
| KR20110007151A (en) | 2011-01-21 |
| TW201004719A (en) | 2010-02-01 |
| JP2011515216A (en) | 2011-05-19 |
| WO2009120330A2 (en) | 2009-10-01 |
| WO2009120344A3 (en) | 2010-10-07 |
| WO2009120330A3 (en) | 2010-09-16 |
| US20110017287A1 (en) | 2011-01-27 |
| TW200952191A (en) | 2009-12-16 |
| WO2009120344A2 (en) | 2009-10-01 |
| US20100307552A1 (en) | 2010-12-09 |
| JP2011515866A (en) | 2011-05-19 |
| AU2009229329A1 (en) | 2009-10-01 |
| CN102036757A (en) | 2011-04-27 |
| AU2009229343A1 (en) | 2009-10-01 |
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